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Root Cause Analysis in Manufacturing Operations

Updated: Nov 15, 2023

Every manufacturing process has its inefficiencies and these inefficiencies often lead to losses that harm their bottom line. When you have production problems in your manufacturing process, it’s essential to find and solve those concerns before they impact your company on a huge scale. Usually, the more complex the process, the more complex the problems tend to be and that’s where root cause analysis (RCA) comes in. Once you have the concern under control, it is important to know how to keep away from it, so it doesn’t happen again. To do this, practicing and enhancing root cause analysis is your best solution.

So what is this root cause analysis? The online Collins Dictionary defines a root cause as: “The fundamental reason for the occurrence of a problem.” It says that the first recorded usage of “root cause” was sometime in the late 1800s. Root Cause Analysis is the process of tracking the causes of an observable issue and recognizing the basic underlying concern that was causing it. On the production floor, Root Cause Analysis (RCA) identifies factors that cause defects or quality deviations in the manufactured product.

Solving the Problem from Its Origins

Root cause analysis can bring many tangible and intangible benefits to a business. Some of these benefits include: Early detection of defects: The main benefit of root cause analysis is that it finds the fundamental defects in the development process, enabling teams to enact the right measures to fix the problems instantly and stop them from recurring ahead. Hence, there is a lesser rework and fewer defects in the final product. Minimize cost by solving problems once: Simply stated, solving the problem once is clearly the more cost-effective solution. Manufacturers do not have the luxury to waste precious resources this way. RCA helps them prevent this, and this is precisely why manufacturing companies use it. Automation: A root cause analysis system can share information across factories within the same company, allowing managers to record notes concerning a common root cause and take steps to prevent it from happening at their own plant. Sometimes, it’s relatively simple to solve a particular problem, particularly when that problem stems from a single cause or a factor that’s easy to spot. But very often this is not the case. Sometimes, the problem is caused by a complex combination of factors, making the root cause more difficult to understand. This is why most manufacturers simply come to accept a certain amount of production losses: they’ve applied their smartest, most talented process experts and advanced tools to the problem, and simply couldn’t see what was wrong. What do you think they should do? Experience and process expertise is of course invaluable. The problem is, for many complex processes, it isn’t humanly possible to analyze all the combinations of all the data tags on a production line, all the time. And that’s where artificial intelligence comes in.

Root Cause Analysis in Real-Time: Khenda Analyze

Khenda Analyze is an excellent solution for analyzing production progress in real-time. It offers high visibility of performance and real-time awareness so operators can easily retrospectively review for quality errors with video records. In this way, operators and managers can quickly fix the problems. Khenda Analyze is a huge short-term solution providing continuous real-time data flow in each production line. Besides companies can accelerate operator training with video datasets and transform their manual production lines with the power of AI. We not only offer an accurate view of downtime but the platform where you will be able to determine where the problem is. Check how AI-based video recording system can help you to improve manufacturing strategies and eliminate the obstacles to success. Ready to take your next step in finding out the root cause of your problem? For more information, you can reach out to us at References


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